Device for formfree printing a three-dimensional object in layers

ABSTRACT

According to various embodiments, a device for formfree printing a three-dimensional object in layers using at least one printing material includes: at least one printing head to output printing material in at least one printing material string; a printing platen to receive the at least one printing material string output by the at least one printing head; a rod-shaped heating device movably arranged over the printing platen; a heat controller configured to control the rod-shaped heating device to emit a heat irradiation directed to the printing platen to heat the at least one printing material string; at least one motor coupled to the rod-shaped heating device to move it over the printing platen; a motor controller configured to control the at least one motor to move the rod-shaped heating device over the printing platen to harden the at least one printing material string printed on the printing platen.

TECHNICAL FIELD

Various embodiments relate generally to a device for formfree printing athree-dimensional object in layers.

BACKGROUND

Additive manufacturing is a rapidly growing field including varioustypes of different techniques to create a three-dimensional objectlayer-by-layer under computer control. Additive manufacturing may bealso referred to as three-dimensional printing (3D-printing) in a verybroad sense. The nomenclature of additive manufacturing techniques isnot necessarily uniformly chosen, however, there may be different mainconcepts in this field, as for example, binder jetting, directed energydeposition, material extrusion, material jetting, powder bed fusion,sheet lamination and vat photo polymerization. The different additivemanufacturing techniques may vary in the way the desiredthree-dimensional shape of the object is generated, e.g. the way thesuccessive layers are provided, in combination with a suitable materialfor this method. Extrusion type additive manufacturing techniques mayinclude for example fused deposition modeling (FDM) or fused filamentfabrication (FFF) and robocasting or direct ink writing. Powder bed typeadditive manufacturing techniques may include for example binder jetting(also referred to as powder bed and inkjet head 3D printing, 3DP),electron-beam melting (EBM), selective laser melting (SLM), selectiveheat sintering (SHS), selective laser sintering (SLS), and direct metallaser sintering (DMLS). Light polymerized type additive manufacturingtechniques may include for example stereolithography (SLA) and digitallight processing (DLP). Further, there may be various other types ofadditive manufacturing techniques.

SUMMARY

According to various embodiments, a device for formfree printing athree-dimensional object in layers using at least one printing materialmay include at least one printing head to output printing material in atleast one printing material string, a printing platen to receive the atleast one printing material string output by the at least one printinghead, a rod-shaped heating device movably arranged over the printingplaten, a heat controller configured to control the rod-shaped heatingdevice to emit a heat irradiation directed to the printing platen toheat the at least one printing material string, at least one motorcoupled to the rod-shaped heating device to move it over the printingplaten, and a motor controller configured to control the at least onemotor to move the rod-shaped heating device over the printing platen toharden the at least one printing material string printed on the printingplaten.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. The drawings are not necessarilyto scale, emphasis instead generally being placed upon illustrating theprinciples of the invention. In the following description, variousembodiments of the invention are described with reference to thefollowing drawings, in which:

FIG. 1A and FIG. 1B respectively show a device for formfree printing athree-dimensional object in layers in a schematic view, according tovarious embodiments;

FIGS. 2A and 2B respectively show a device for formfree printing athree-dimensional object in layers in a schematic view, according tovarious embodiments; and

FIG. 3 shows a device for formfree printing a three-dimensional objectin layers in a schematic view, according to various embodiments; and

FIGS. 4A to 4F show a device for formfree printing a three-dimensionalobject in layers in a schematic view, according to various embodiments..

DESCRIPTION

The following detailed description refers to the accompanying drawingsthat show, by way of illustration, specific details and embodiments inwhich the invention may be practiced.

The word “exemplary” is used herein to mean “serving as an example,instance, or illustration”. Any embodiment or design described herein as“exemplary” is not necessarily to be construed as preferred oradvantageous over other embodiments or designs.

Various embodiments relate to an additive manufacturing process and to adevice for creating a three-dimensional object via this additivemanufacturing process, also referred to herein as printing device.According to various embodiments, the additive manufacturing process maybase on a printing technique for successively forming the layers of thethree-dimensional object. Therefore, a printing head is used to depositthe printing material for the respective layer.

In general, various printing materials may be used for additivemanufacturing based on successively forming layers by printing, e.g.thermoplastic materials, pastes, duroplastic materials, low meltingpoint metals, and the like. Thermoplastic materials may include, forexample, polyamide (e.g. aliphatic polyamide), polyethylene,acrylonitrile butadiene styrene (ABS), a polyester, e.g.polycaprolactone (PCL), polycarbonate, Polylactic Acid (PLA),Polypropylene (PP), and/or mixtures thereof, etc. A substance used asprinting material may be a paste or a liquid or any other materialsuitable for printing. A paste may behave as a solid until asufficiently large load or stress is applied, at which point it flowslike a fluid. Further, the temperature of the printing material may beadapted, e.g., via heating the printing material in the printing head,to change the viscosity of the printing material to allow printing or tooptimize the printing result using the heated printing material.

However, it is to be noted that various embodiments may process othersuitable printing materials as described above or as will be describedin more detail below.

According to various embodiments, a printing material may be usedincluding only one polymer or a blend of more than one polymer. Theprinting material may be configured that a polymerization may betriggered after the printing material has been printed. For example, aresin blend may be used as printing material, wherein the polymerizationof the resin blend may be triggered by electromagnetic radiation and/orby heat (thermosetting polymer resin blends). To allow a triggeredpolymerization catalysts and/or initiators may be used.

FIG. 1A illustrates a device 100 for formfree printing athree-dimensional object in layers in a schematic view, according tovarious embodiments. FIG. 1B illustrates the device 100 for formfreeprinting a three-dimensional object in layers in a schematic top view,according to various embodiments. As illustrated in FIG. 1A, the device100 may include at least one printing head 102. The printing head 102may be configured to output printing material 104 in at least oneprinting material string 104 s. Therefore, the printing head 102 mayinclude a nozzle 102 d or the like to output the printing material 104in string-shape.

According to various embodiments, the device 100 may further include aprinting platen 106. The printing platen 106 may be configured toreceive the at least one printing material string 104 s output by the atleast one printing head 102. The printing platen 106 may be arrangedbelow the printing head 102, or, in other words, the printing head 102may be arranged relative to the printing platen 106 so that the materialstring 104 s can be deposited on the printing platen 106 as desired. Theprinting platen 106 may be coupled to an adjustment mechanism (notillustrated) that allows adjusting the position and/or the orientationof the printing platen 106 relative to the printing head 102. Further,e.g., optionally, the printing head 102 may be coupled to an adjustmentmechanism (not illustrated) that allows adjusting the position and/ororientation of the printing head 102 relative to the printing platen106. Further, the printing head 102 may be coupled to a drive mechanism(not illustrated) that allows moving the printing head 102 relative tothe printing platen 106 in any desired way, e.g., the drive mechanismmay be configured to allow driving the printing head 102 along anx-axis, y-axis, and/or z-axis. Further, e.g., optionally, the drivemechanism may be configured to allow tilting the printing head 102around the x-axis, y-axis, and/or z-axis.

According to various embodiments, the device 100 may further include arod-shaped heating device 108. The rod-shaped heating device 108 may bemovably arranged 108 h over the printing platen 106. According tovarious embodiments, the rod-shaped heating device 108 may be coupled toan adjustment mechanism (not illustrated) that allows adjusting theposition and/or orientation of the rod-shaped heating device 108relative to the printing platen 106. According to various embodiments,the rod-shaped heating device 108 may be movably arranged via at leastone guide system or rail system defining a movement plane or a movementdirection of the rod-shaped heating device 108 relative to the printingplaten 106. According to various embodiments, one or more motors 138 maybe used for moving 108 h the rod-shaped heating device 108 relative tothe printing platen 106. In other words, the device 100 may furtherinclude at least one motor 138 coupled to the rod-shaped heating device108 to move the rod-shaped heating device 108 over the printing platen106. The rod-shaped heating device 108 may be movably arranged 108 h insuch a way, that the rod-shaped heating device 108 can be moved in adirection (e.g., direction 101 illustrated in FIGS. 1A and 1B) or on aplane (e.g., the plane defined by the directions 101, 103 illustrated inFIGS. 1A and 1B) parallel to the surface 106 s of the printing platen106. The device 100 may further include a motor controller 148. Themotor controller 148 may be configured to control the at least one motor138 to move the rod-shaped heating device 108 over the printing platen106. This may allow hardening the at least one printing material string104 d output by the printing head 102 (also referred to as printed) onthe printing platen 106. The hardening may be used to solidify theprinting material 104 deposited on the printing platen 106, since theprinting material 104 may be liquid or viscous to allow printing via theprinting head 102.

According to various embodiments, the device 100 may further include aheat controller 118. The heat controller 118 may be configured tocontrol the rod-shaped heating device to emit a heat radiation 128directed to the printing platen 106 to heat the at least one printingmaterial string 104 d deposited onto the printing platen 106.

Illustratively, the rod-shaped heating device 108 may be coupled to adrive mechanism 138, 148 that allows moving the rod-shaped heatingdevice 108 relative to the printing platen 106 in any desired way, e.g.,the drive mechanism may be configured to allow driving the printing head102 along an x-axis, y-axis, and/or z-axis. Further the drive mechanism138, 148 may be configured to allow tilting the rod-shaped heatingdevice 108 around the x-axis, y-axis, and/or z-axis. The tilting of therod-shaped heating device 108 may be used to align the rod-shapedheating device 108 relative to the printing platen 106 to provide ahomogeneous irradiation of the printing platen 106 or of the printingmaterial string 104 d output by the printing head 102 onto the printingplaten 106. Further, a pre-defined distance (e.g., along direction 105illustrated in FIG. 1A) between the rod-shaped heating device 108 andthe printing platen 106 may be provided to generate a desiredirradiation of the printing platen 106 or of the printing materialstring 104 d output by the printing head 102 onto the printing platen106. After alignment, the rod-shaped heating device 108 may be movedonly along one direction (e.g., direction 101 illustrated in FIGS. 1Aand 1B) parallel to the surface 106 s of the printing platen 106 or in aplane (e.g., the plane defined by the directions 101, 103 illustrated inFIGS. 1A and 1B) parallel to the surface 106 s of the printing platen106.

The device 100 for formfree printing a three-dimensional object inlayers may be used to successively deposit (also referred to assuccessively print) printing material 104 s in layers 104 d onto theprinting platen 106 to provide the three-dimensional object in thedesired size and shape. The printing of the layers may be computerassisted, as commonly used for additive manufacturing andthree-dimensional printing.

According to various embodiments, the rod-shaped heating device 108 mayinclude a rod-shaped lamp, e.g., a UV-lamp for emitting ultra-violet(UV) radiation (also referred to UV light) or an IR-lamp for emittinginfrared (IR) radiation (also referred to IR light). Therefore, therod-shaped lamp may be configured to emit light having a wavelength inthe range from about 100 nm to about 380 nm. Alternatively, therod-shaped lamp may be configured to emit light having a wavelength inthe range from about 780 nm to about 1 mm.

According to various embodiments, the rod-shaped heating device 108(e.g., the rod-shaped lamp) may have a length 103 b of approximately thesame or greater than the width 103 a of the printing platen 106 so thatthe radiated heat 128 is irradiated on substantially the entire width103 a of the printing platen 106. In other words, the rod-shaped heatingdevice 108 may be configured to irradiate the entire surface 106 s ofthe printing platen 106 by linearly moving 108 h the rod-shaped heatingdevice 108 over the printing platen 106, wherein the rod-shaped heatingdevice 108 may be configured so that the axial extension (e.g., theextension along direction 103 as illustrated in FIG. 1B) of therod-shaped heating device 108 is aligned at any angle excluding aparallel arrangement (e.g., perpendicular or at an angle between 45° and90°) to the moving direction 108 h (e.g., along direction 101 asillustrated in FIG. 1B).

As illustrated in FIG. 1B, the printing platen 106 may have an effectiveprinting area 106 p that may be smaller than the size of the printingplaten 106, e.g., an effective printing width 103 c that is less thanthe width 103 a of the printing platen 106. Further, the rod-shapedheating device 108 may have an effective heating length 103 d (i.e. theaxial extension) that may be less than the length 103 b of therod-shaped heating device 108. The effective heating length 103 d may bedefined by the actual region of the rod-shaped heating device 108homogeneously emitting heat. For example, a heating lamp of therod-shaped heating device 108 may be shorter than the rod-shaped heatingdevice 108 itself including for example additional structures (e.g.,lamp sockets, etc.). In this case, the effective heating length 103 d ofthe rod-shaped heating device 108 (e.g., the rod-shaped lamp) may be thesame or greater than the effective printing width 103 c of the printingplaten 106 so that the heat 128 radiated by the rod-shaped heatingdevice 108 is irradiated on substantially the entire effective printingarea 106 p of the printing platen 106. In other words, the rod-shapedheating device 108 may be configured to irradiate the effective printingarea 106 p of the printing platen 106 by linearly moving 108 h therod-shaped heating device 108 over the printing platen 106, as describedbefore.

According to various embodiments, the rod-shaped heating device 108(e.g., the rod-shaped lamp, etc.) may have a length in the range fromabout 10 cm to about 2 m, e.g., in the range from about 10 cm to about 1m. According to various embodiments, the printing platen 106 may have awidth less than about the length of the rod-shaped heating device 108.

According to various embodiments, the motor controller 148 may befurther configured to control the at least one motor 138 to move therod-shaped heating device 108 over the printing platen 106 at least onceeach time after a respective layer of the at least one printing materialstring 104 d has been printed on the printing platen 106.Illustratively, after printing and before printing the next layer, eachprinted layer of the successively printed layers may be irradiated bymoving the rod-shaped heating device 108 over the printing platen 106 atleast once, e.g., twice.

According to various embodiments, the heat controller 118 may be furtherconfigured to control the rod-shaped heating device 108 to emit a heatirradiation 128 directed to the printing platen 106 to heat the at leastone printing material string 104 d to a reaction temperature of the atleast one printing material of the at least one printing material string104 d. Illustratively, a reactive printing material may be used tosuccessively print the layers forming the desired three-dimensionalobject, wherein the chemical reaction of the printing material may betriggered by subjecting the printing material to radiation 128 (e.g.heat radiation, also referred to IR-light) emitted by the rod-shapedheating device 108. According to various embodiments, the printingmaterial may be a thermosetting material, e.g., a thermosetting polymermaterial or a thermosetting polymer material blend, wherein the chemicalreaction may be a polymerization of the thermosetting material.

According to various embodiments, the device 100 may further include areservoir 202 to receive the at least one printing material 104, asrespectively illustrated in FIG. 2A and FIG. 2B in a schematic view.According to various embodiments, the reservoir 202 may be coupled tothe at least one printing head 102 to supply the at least one printingmaterial 104 to the at least one printing head 102. The reservoir 202may be part of the printing head 102 or may be provided separated fromthe printing head 102 feeding the printing material to the printing head102 via one or more feeding lines.

As illustrated in FIG. 2B, the device 100 may further include a firstpre-reservoir 202 a to receive a first pre-printing liquid 204 a and asecond pre-reservoir 202 b to receive a second pre-printing liquid 204b. The pre-reservoir 202 a, 202 b may be configured to provide the firstpre-printing liquid 204 a and the second pre-printing liquid 204 b tothe reservoir 202. The reservoir 202 may be configured to provide the atleast one printing material 104 from the first pre-printing liquid 204 aand the second pre-printing liquid 204 b. Illustratively, the firstpre-printing liquid 204 a and the second pre-printing liquid 204 b aremixed to thereby obtain the at least one printing material 104. Thereservoir 202 and the pre-reservoir 202 a, 202 b may be part of theprinting head 102 or may be provided separated from the printing head102 feeding the printing material to the printing head 102 via two ormore feeding lines.

According to various embodiments, the first pre-printing liquid 204 aand the second pre-printing liquid 204 b may be components of athermosetting printing material 104 or any other reactive printingmaterial 104, where the chemical reaction may be triggered by therod-shaped heating device 108. In the same way, a rod-shaped radiationemitting device 108 may be used, wherein the first pre-printing liquid204 a and the second pre-printing liquid 204 b may be components of achemically reactive printing material 104, where the chemical reactionmay be triggered by the rod-shaped radiation emitting device 108.

According to various embodiments, a dosage controller 214 may be used todose (e.g., via a dosing unit controlled by the dosage controller 214)the at least one printing material 104 supplied to the reservoir 202, asschematically illustrated in FIG. 2A and FIG. 2B. According to variousembodiments, the dosage controller 214 may be configured to dose (e.g.,via a dosing unit controlled by the dosage controller 214) the amount ofthe first pre-printing liquid 204 a and the amount of the secondpre-printing liquid 204 b supplied to the reservoir 202, asschematically illustrated in FIG. 2B. The pre-printing liquids 204 a,204 b may be also referred to as components of the printing material104.

According to various embodiments, a device for mold-free (in other wordsformfree) printing (also referred to das additive manufacturing or3D-printing) a three-dimensional object via successively formed layersusing at least one printing material may be provided in a similar way asdescribed above referring to FIGS. 1A to 2B. The device for mold-freeprinting a three-dimensional object via successively formed layers usingat least one printing material may include: a printing platen 106; atleast one printing head 102 configured to output 104 s (in other wordsto print, e.g. to extrude or to string-shaped extrude) the at least oneprinting material 104 and to form at least one printing material deposit104 d on the printing platen(via the at least one printing materialoutput 104 s by the at least one printing head 102); and a rod-shapedheating device 108 arranged over the printing platen 106 in a moveableconfiguration 108 h allowing movement of the rod-shaped heating device108 over the printing platen 106, wherein the rod-shaped heating device108 may be configured to emit heat radiation 128 directed at theprinting platen 106 to harden the at least one printing material deposit104 d via the heat radiation. The at least one printing head 102 may beoptionally configured to output the at least one printing material 104in a string-shape 104 s, as described above.

The device may further include a motor arrangement 138, 148 configuredto drive movement of the rod-shaped heating device 108. According tovarious embodiments, the motor arrangement 138, 148 may include at leastone motor 138 coupled to the rod-shaped heating device 108 and at leastone motor controller 148 configured to control the driven movement ofthe rod-shaped heating device 108 via the at least one motor 138. Thedevice may further include a heating device controller 118 configured tocontrol emission of the heat radiation 128 from the rod-shaped heatingdevice 108.

A dosage controller 214 may include a control circuit and at least onedosing unit controlled by the control circuit. The dosage controller 214may be part of a dispensing system, the at least one dosing unit may bealso referred to as dispenser. According to various embodiments, thedispensing system used to dispense the printing material 104 and/or thepre-printing liquids 204 a, 204 b (see FIGS. 2A and 2B) may include onedispenser or more than one dispenser. The dispenser may include at leastone valve. Alternatively, valve-free dispenser may be used, e.g., adispenser based one a rotatable mounted scroll structure disposed withina hollow tube. According to various embodiments, the dosage controller214 may be configured to provide a suck-back process at the end of eachdosing step, e.g., by changing the rotation direction of the rotatablemounted scroll structure. The, e.g., valve-free, dispenser may be alsoreferred to as a pump.

The dispenser may provide the printing material 104 for the printinghead 102 and the dosage controller 214 may be used to control the flowof the printing material 104 out of the printing head 102. In otherwords, the output of the printing material 104 may be controlled by thedosage controller 214. According to various embodiments, the dosagecontroller 214 may be part of the printing head 102 or may be arrangedseparated from the printing head 102.

In the case, that a two-component 204 a, 204 b printing material 104 isused (or in a similar way a printing material based on more than twocomponents), each of the components 204 a, 204 b may be extracted fromtheir pre-reservoir 202 a, 202 b (e.g., from any suitable container) andmixed in a predefined ratio to provide the printing material in thereservoir 202 (see FIG. 2B).

Further, a single-component printing material 104 may be provided to thereservoir 202 from any suitable container directly (see. FIG. 2A).However, also a two-component printing material may be mixed in advanceand provided as pre-mixed printing material directly to the printinghead 102.

To extract a pre-printing liquid 204 a, 204 b and/or a printing material104 from a reservoir, any suitable emptying system may be used.According to various embodiments, any suitable printing device may beused that is based on a X,Y,Z-axis setup. According to variousembodiments, the printing head 102 may be configured as dispenser ordispenser system for dosing single-component or two-component (ormulti-component) printing materials. The dispenser or dispenser systemfor two-component 204 a, 204 b (or multi-component) printing materials104 may include a mixer two provide a homogeneously mixed printingmaterial 104. The mixer may be arranged to receive the components 204 a,204 b in the predefined ratio to provide the printing materials 104 withthe desired composition. The mixer may be a static mixer and the mixingratio may be controlled by the dosage controller 214.

According to various embodiments, the rod-shaped heating device 108 mayinclude one or more short-wave infrared tube radiator (e.g., short-waveinfrared tube radiator from the manufacturer HEWID® Heizelemente GmbH).The short-wave infrared tube radiator may emit substantially radiationin the wavelength range from about 780 nm to about 3500 nm. However, oneor more other suitable infrared radiator may be used, e.g., one or moreceramic radiator that emit heat by converting electrical energy, and thelike. The IR-tube radiator may be mounted along the Y-axis of theprinter, for example. The emission of the rod-shaped heating device 108may be controlled by a heating current provided through at least oneheating element of the rod-shaped heating device 108. The heatingelement may be or may include a heat resistor structure. According tovarious embodiments, the rod-shaped heating device may include areflector structure configured to emit radiation substantially into thedirection of the printing platen 106.

According to various embodiments, a dispenser (e.g., from themanufacturer ViscoTec) may be used as a printing head in athree-dimensional printer (also referred to herein as printing device),e.g., in an X400 printer of the manufacturer German RepRap. The printingmaterial 104 or the pre-printing liquids 204 a, 204 b may be stored inone or more containers, e.g., spatially separated from thethree-dimensional printer itself. The printing material 104 or thepre-printing liquids 204 a, 204 b may be fed from the one or morecontainers to the dispenser via a pump arrangement (also referred to asemptying system). For feeding the printing material 104 or thepre-printing liquids 204 a, 204 b to the dispenser, one or more supplylines (e.g., one or more hoses, e.g., one or more tubes) may be used.According to various embodiments, one separate supply line for each ofthe components of the printing material 104 may be provided.

According to various embodiments, the control system of the printingdevice (e.g., device 100) described herein may be configured to providea direct communication controlling the dispenser movement, the mixing ofthe pre-printing liquids 204 a, 204 b (if necessary) and the infraredtube radiator, e.g., including the temperature control for the infraredtube radiator.

According to various embodiments, FIG. 3 schematically illustrates aprocess flow for formfree printing a three-dimensional object in layersmay include a material supply and a process of additive manufacturingthe three-dimensional object in a desired shape, e.g., using a2-component 204 a, 204 b printing material 104 and a suitably configuredprinting device 100, as described herein.

According to various embodiments, the two printing material components204 a, 204 b (also referred to as pre-printing liquids) may be fed fromthe respective containers 202 a, 202 b (also referred to aspre-reservoir), e.g., unmixed, to the dispenser 304, e.g., via anemptying system. The dispenser 304 may be mounted in a printing deviceas a printing head 102 and may be addressed computer controlled in asimilar way as a printing head 102, as described above. The dispenser304 may include two separately controllable pumps 304 p. For example,for each of the two printing material components 204 a, 204 b aseparately controllable pump 304 p may be used. The pumps 304 p may feedthe two printing material components 204 a, 204 b to a mixer 304 m(e.g., to a static mixer) in a controlled manner. The mixer 304 m may bearranged below the pumps 304 p and may be part of the dispenser 304 ormay be coupled to the dispenser 304. The mixer 304 m may feed the mixedprinting material 104 to a nozzle 304 n to output the mixed printingmaterial 104 through the nozzle 304 n. The nozzle may have a pre-definedoutput diameter, e.g., adapted to the viscosity of the mixed printingmaterial 104.

According to various embodiments, each of the printing materialcomponents 204 a, 204 b may be provided under a pressure in the rangefrom about 1 bar to 3 bar, e.g., a pressure of about 2 bar, to therespective pump input of the pumps 304 p. The pressure may be providedand controlled by the emptying system. The pumps 304 p may be configuredas rotation pumps including at least one scroll element for controllingthe material output to the mixer 304 m based on the rotational speed ofthe at least one scroll element. The pumps 304 p may be configured tofeed the printing material components 204 a, 204 b to the mixer 304 m ina predefined mixing ratio. The mixing ratio may be adjusted to thepredefined value by controlling the rotational speed of the at least onescroll element of the respective pump 304 p (e.g., a greater rotationalspeed may allow to feed more material to the mixer as a less rotationalspeed).

As an example, to obtain a mixing ratio of 1:1 both pumps may beoperated with the same number of rotations per minute (rpm), i.e. withthe same rotational speed. As another example, to obtain a mixing ratioof 1:2 the material pump 304 p for the second material component 204 bmay be operated with twice the number of rotations per minute (rpm) asthe material pump 304 p for the first material component 204 a.

Both pump outputs may be coupled directly to the mixer 304 m. In themixer, the two material components 204 a, 204 b may be mixed with eachother. The mixer 304 m may be coupled directly to the nozzle 304 n.Further, the mixed printing material 104 may be output by the nozzle 304n (see also FIG. 1A illustrating a similar configuration).

According to various embodiments, the process of additive manufacturingmay include providing printing data (e.g., provided in gcode) forcontrolling the printing device 100, as descried herein. The printingdata may be transmitted to a device controller of the printing device100 and the device controller may further process the printing data.According to various embodiments, the dispenser 304 may be controlled bythe device controller as a printing head, e.g., the dispenser 304 may bemoved over the printing platen 106 as defined in the printing data toform a three-dimensional object in a desire size and shape. The devicecontroller may further control the mixing of the material components 204a, 204 b of the printing material 104. A communication interface (e.g.,a communication interface circuit) may be provided to define the mixingratio of the material components 204 a, 204 b. Alternatively, the devicecontroller may be configured to communicate with a mixing controller,wherein the mixing controller may be configured to control a mixingratio of the material components 204 a, 204 b of the printing material104. A communication interface (e.g., a communication interface circuit)may be provided directly at the mixing controller to define the mixingratio of the material components 204 a, 204 b. According to variousembodiments, the mixing ratio may be adapted before and/or during theadditive manufacturing process, i.e. before and/or during operating theprinting device 100, as described herein.

According to various embodiments, the printing process may includemoving the dispenser along a predefined path by controlling the X-axisand Y-axis movement of the dispenser. Further, the dispenser may outputthe mixed printing material 104 directly onto the printing platen 106.The printing platen 106 may include or may consist of a glass-ceramic.However, other materials may be used to provide the printing platen 106.

According to various embodiments, after printing of a layer has beenfinished, the dispenser 304 may be moved away from the printing objectto provide space for the rod-shaped heating device 108 (e.g., for theinfrared tube radiator or any other suitable radiation emitting device)to move over the printing platen 106. Subsequently, the rod-shapedheating device 108 may be activated and set to a material-specificreaction temperature to harden the printing material 104 d (see FIGS. 1Aand 1B). The rod-shaped heating device 108 may be moved with a fixeddistance to the printing platen 106 and/or to the printed material layer104 d directly over the printed material layer 104 d. According tovarious embodiments, the rod-shaped heating device 108 may be moved atleast one time (e.g., two times) over the printed material layer 104 d.According to various embodiments, the rod-shaped heating device 108 maybe moved two times over the printed material layer 104 d, once back andforth.

Subsequently, the z-axis distance of the dispenser to the printingplaten 106 may be increased for printing the next layer of thesuccessively printed layers to form the three-dimensional object in adesired shape and size.

According to various embodiments, the processes of printing a layer viathe mixed printing material and hardening (also referred to as curing,activating, triggering, and the like) the mixed printing material of theprinted layer may be repeated alternatingly.

After a few seconds, the mixed printing material may be stable. Thegenerated object may be taken out of the device 100 (e.g., may beremoved from the printing platen 106) after a few minutes.

According to various embodiments, the above process may be carried outusing various types of printing materials. Such printing materials mayinclude those reactive liquid materials, which may be injected in theprinting device and cure/react upon heating to form a printed object ora (or multiple) printed layer(s) of an object. However, other suitablematerials may be used in various embodiments.

Such materials include resins, some of which may be cured by UV light;silicone rubbers. Further materials include thermoplastics, such asacrylonitrile butadiene styrene (ABS), polycarbonate, nylon,polyetherimide (PEI) resin.

For the sake of examples, the present device is used featuring a3D-printable silicone rubber composition.

3D-printable silicone rubber compositions typically cure or react toprovide 3D-printed silicone rubber articles, also referred to as3D-printed silicone elastomer articles or 3D-printed silicone rubbers.The terms silicone rubber and silicone elastomer may be usedinterchangeably. 3D-printable silicone rubber compositions includeplatinum cured silicone rubbers (addition reaction, otherwise known ashydrosilylation).

Various effects of 3D-printed silicone rubbers may include low scaleapplication without need of reproducing molds, easy prototyping allowingto avoid injection molding, precision printing of small or uniquepieces.

Organopolysiloxanes may generally be described as polymers havingmultiple units of the formula (I):

R_(a)SiO_((4−a)/2)  (I)

in which R is independently selected from hydrogen, aliphatichydrocarbyl, aromatic hydrocarbyl, or organyl group (that is any organicsubstituent group, regardless of functional type, having one freevalence at a carbon atom). Saturated aliphatic hydrocarbyls areexemplified by, but not limited to alkyl groups such as methyl, ethyl,propyl, pentyl, octyl, undecyl, and octadecyl and cycloalkyl groups suchas cyclohexyl. Unsaturated aliphatic hydrocarbyls are exemplified by,but not limited to, alkenyl groups such as vinyl, allyl, butenyl,pentenyl, cyclohexenyl and hexenyl; and by alkynyl groups. Aromatichydrocarbon groups are exemplified by, but not limited to, phenyl,tolyl, xylyl, benzyl, styryl, and 2-phenylethyl. Organyl groups areexemplified by, but not limited to, halogenated alkyl groups such aschloromethyl, 3-chloropropyl, and 3,3,3-trifluoropropyl; nitrogencontaining groups such as amino groups, amido groups, imino groups,imido groups; oxygen containing groups such as polyoxyalkylene groups,carbonyl groups, alkoxy groups and hydroxyl groups. Further organylgroups may include sulfur containing groups, fluor containing groups,phosphorus containing groups, boron containing groups. The subscript “a”is an integer of from 0 to 3.

Siloxy units may be described by a shorthand (abbreviated) nomenclature,namely—“M,” “D,” “T,” and “Q”, when R is a methyl group (furtherteaching on silicone nomenclature may be found in Walter Noll, Chemistryand Technology of Silicones, dated 1962, Chapter I, pages 1-9). The Munit corresponds to a siloxy unit where a=3, that is R₃SiO_(1/2); the Dunit corresponds to a siloxy unit where a=2, namely R₂SiO_(2/2); the Tunit corresponds to a siloxy unit where a=1, namely R₁SiO_(3/2); the Qunit corresponds to a siloxy unit where a=0, namely SiO_(4/2).

A typical 3D-printable silicone rubber composition may include:

-   -   an organopolysiloxane (A) containing at least 2 alkenyl groups        bonded to silicon atom per molecule,    -   an organopolysiloxane (B) containing at least 3 silicon-bonded        hydrogen atom per molecule,    -   a platinum based catalyst (C),    -   an optional inhibitor (D),    -   an optional silica filler (E).

The platinum based catalyst is added in an amount sufficient to effectand initiate the cure of the organopolysiloxanes (A) and (B). Theinhibitor of the platinum based catalyst is optional. It is typicallyused to stabilize the composition before curing is effected, byinhibiting the cure catalyst. The silica filler may be present toreinforce the 3D-printed silicone elastomer and/or to influence therheological properties of the 3D-printable composition in the uncuredstage.

A typical molar ratio of inhibitor to the platinum atom of the catalystusually ranges of from 20 to 100, that is, the molar ratio of inhibitorto the platinum atom is typically comprised of from 20:1 to 100:1.

The cure temperature of a typical 3D-printable silicone rubbercomposition may range of from 100 to 220° C., alternatively 120 to 190°C., alternatively 140 to 180° C. The present operating device mayhowever function at temperatures of from 20° C. to 250° C.

The organopolysiloxane (A) may have any structure. Theorganopolysiloxane (A) may be a linear, branched or resinous polymer.

The organopolysiloxane (A) contains at least 2 alkenyl groups bonded tosilicon atom per molecule. Examples of alkenyl groups include vinyl,allyl, butenyl, pentenyl, cyclohexenyl and hexenyl groups. These may bependent or terminal or at both positions, that is, they may be presenton any of the siloxy units of the organopolysiloxane (A).

The viscosity of organopolysiloxane (A) at 25° C. is typically within arange of from 0.1 to 100 Pa·s. Unless otherwise indicated, allviscosities are measured using a rotational viscometer such as aBrookfield viscometer, or by using a capillary rheometer.

The organopolysiloxane (A) may contain phenyl groups.

The organopolysiloxane (A) may contain fluorine containing groups suchas trifluoropropyl groups.

Examples of the organopolysiloxane (A) which may be used includevinyldimethylsiloxy-endblocked dimethylsiloxane-vinylmethylsiloxanecopolymer, vinyldimethylsiloxy-endblocked polydimethylsiloxane,vinylmethylhydroxysiloxy-endblocked dimethylsiloxane-vinylmethylsiloxanecopolymer, vinyldimethylsiloxy-endblockeddimethylsiloxane-vinylmethylsiloxane copolymer, and mixtures thereof.

The organopolysiloxane (A) may be either a single polymer, or acombination of two or more different polymers.

The organopolysiloxane (A) is present in the formulation at a level offrom 35 to 85% by weight, based on the total weight of the composition.

The organopolysiloxane (B) is an organopolysiloxane containing at least3 silicon-bonded hydrogen atom per molecule conforming to the generalformula (II):

(R₃SiO_(1/2))_(y)(RHSiO_(2/2))_(z)(R₂SiO_(2/2))_(p)   (II)

where R is as described above (independently selected from hydrogen,aliphatic hydrocarbyl, aromatic hydrocarbyl, or organyl group), and H ishydrogen and

where y=2, z≤3, p>0.

The viscosity of organopolysiloxane (B) at 25° C. is not critical. Theviscosity of organopolysiloxane (B) at 25° C. may range of from 0.1 to1000 mPa·s, alternatively of from 1 to 500 mPa·s.

The organopolysiloxane (B) is generally present in the 3D-printablesilicone elastomer composition in an amount of from 0.1 to 15% byweight, based on the total weight of the composition.

Addition-reaction catalysts are well known in the art. These includecatalysts selected form the platinum group metals, or transition metals,of the periodic table of the elements, such as platinum, ruthenium,rhodium, palladium, osmium and iridium; and compounds thereof.

The catalyst used in the scope of the present invention may be selectedfrom the platinum based catalysts, such as chloroplatinic acid,chloroplatinic acid dissolved in an alcohol or a ketone and thesesolutions which have been ripened, chloroplatinic acid-olefin complexes,chloroplatinic acid-alkenylsiloxane complexes, chloroplatinicacid-diketone complexes, platinum black, platinum supported on acarrier, and mixtures thereof.

The catalyst (C) is added in a quantity sufficient to cure theorganopolysiloxane (A) and the organopolysiloxane (B) present in thecomposition. For example, it may be added in a quantity of platinum atomthat provides of from 0.1 to 500 weight-ppm (parts per million),alternatively of from 1 to 200 weight-ppm, alternatively of from 1 to100 weight-ppm, of platinum atom in the catalyst (C) based on the totalweight of reactive organopolysiloxanes (A) and (B).

Inhibitors of platinum based catalyst are well known in the art.Addition-reaction inhibitors include hydrazines, triazoles, phosphines,mercaptans, organic nitrogen compounds, acetylenic alcohols, silylatedacetylenic alcohols, maleates, fumarates, ethylenically or aromaticallyunsaturated amides, ethylenically unsaturated isocyanates, olefinicsiloxanes, unsaturated hydrocarbon monoesters and diesters, conjugatedeneynes, hydroperoxides, nitriles, and diaziridines.

Examples of acetylenic alcohols and their derivatives include1-ethynyl-1-cyclohexanol (ETCH), 2-methyl-3-butyn-2-ol, 3-butyn-1-ol,3-butyn-2-ol, propargylalcohol, 2-phenyl-2-propyn-1-ol,3,5-dimethyl-1-hexyn-3-ol, 1-ethynylcyclopentanol, 1-phenyl-2-propynol,3-methyl-1-penten-4-yn-3-ol, and mixtures thereof.

The inhibitor (D) may be added in the range of from 10 to 50,000weight-ppm in the 3D-printable silicone elastomer composition.

The silica filler suitable for the present invention may have a specificsurface area measured by BET method of at least 50 m²/g up to 450 m²/g.Examples of silica filler include precipitated silica (wet silica),fumed silica (dry silica), calcined silica, and the like. The silicafiller may be surface-treated, hydrophilic or hydrophobic. The silicamay contain alkenyl group on its surface.

In some instances, the silica contains alkenyl group on its surface.Methods to provide alkenyl groups on silica are known in the art.

The silica filler is present in the composition in an amount of from 10to 40% by weight, based on the total weight of the composition.

Additives may be present in the composition depending on the intendeduse of the 3D-printable silicone elastomer composition. Examples ofadditives include electrical conductive fillers, thermally conductivefillers, non-conductive filler different from silica filler (E), potlife extenders, flame retardants, pigments, dyes, lubricants, adhesionpromoters, fragrances, bleeding additives, mold release agents,diluents, solvents, UV light stabilizers, bactericides, wetting agent,heat stabilizer, compression set additive, plasticizer, etc.

Examples of electrical conductive fillers include metal particles, metaloxide particles, metal-coated metallic particles (such as silver platednickel), metal coated non-metallic core particles (such as silver coatedtalc, or mica or quartz) and a combination thereof. Metal particles maybe in the form of powder, flakes or filaments, and mixtures orderivatives thereof.

Examples of thermally conductive fillers include boron nitride, alumina,metal oxides (such as zinc oxide, magnesium oxide, aluminum oxide),graphite, diamond, and mixtures or derivatives thereof.

Examples of non-conductive fillers, different from silica filler (E),include quartz powder, diatomaceous earth, talc, clay, calciumcarbonate, magnesium carbonate, hollow glass, glass fibre, hollow resinand plated powder, and mixtures or derivatives thereof.

Pot life extenders, such as triazole, may be used, but are notconsidered necessary in the scope of the present invention. The3D-printable silicone elastomer composition may thus be free of pot lifeextender.

Examples of chain extender include straight chain organopolysiloxanescontaining 2 silicon-bonded hydrogen groups on the terminal position.Such chain extender is different from organopolysiloxane (B).

Examples of flame retardants include aluminum trihydrate, chlorinatedparaffins, hexabromocyclododecane, triphenyl phosphate, dimethylmethylphosphonate, tris(2,3-dibromopropyl) phosphate (brominated tris),and mixtures or derivatives thereof.

Examples of pigments include iron oxides, carbon black, and mixtures orderivatives thereof.

Examples of lubricants include tetrafluoroethylene, resin powder,graphite, fluorinated graphite, talc, boron nitride, fluorine oil,silicone oil, molybdenum disulfide, and mixtures or derivatives thereof.

Examples of adhesion promoters include silane coupling agents.

Examples of mold release agents include dimethylhydroxy terminatedpolydimethylsiloxane.

Examples of bleeding additives include phenyl substituted silicone oilsof high viscosity.

Further additives include silicone fluids, such as trimethylsilyl or OHterminated siloxanes. Such trimethylsiloxy or OH terminatedpolydimethylsiloxanes typically have a viscosity<150 mPa·s. When presentsuch silicone fluid may be present in the 3D-printable siliconeelastomer composition in an amount ranging of from 0.1 to 5% weight,based on the total weight of the composition.

The 3D-printable silicone rubber composition may include:

-   -   an organopolysiloxane (A) containing at least 2 alkenyl groups        bonded to silicon atom per molecule, in an amount of from 35 to        85% by weight, based on the total weight of the composition;    -   an organopolysiloxane (B) containing at least 3 silicon-bonded        hydrogen atom per molecule, in an amount of from 0.1 to 15% by        weight, based on the total weight of the composition;    -   a platinum based catalyst (C), in a quantity of platinum atom        that provides of from 0.1 to 500 weight-ppm (parts per million)        of platinum atom in the catalyst (C) based on the total weight        of reactive organopolysiloxanes (A) and (B);    -   an inhibitor (D) selected from the group consisting of        acetylenic alcohols and their derivatives, in an amount of from        10 to 50,000 weight-ppm in the 3D-printable elastomer        composition;    -   a silica filler (E), in an amount of from 10 to 40% by weight,        based on the total weight of the composition;    -   optional additives, in an amount of from 0 to 10% by weight        based on the total weight of the composition, alternatively 0.1        to 10% by weight based on the total weight of the composition.

The 3D-printable silicone rubber may be prepared by:

-   -   firstly, forming a mixture of the 3D-printable silicone rubber        composition, and secondly curing the mixture at a temperature of        from 100 to 220° C.

The 3D-printable silicone rubber composition may readily be prepared inconventional mixing equipment. The order of mixing is not critical ifthe composition is to be used immediately.

The mixture of the 3D-printable silicone rubber composition may beprepared by providing for at least 2 separate parts, such as part I andpart II. Part I may contain the catalyst (C) and any one of theorganopolysiloxane (A) or the silica filler (E), or a combination ofboth. Part II may contain the inhibitor (D) and the organopolysiloxane(B), and any one of the organopolysiloxane (A) or the silica filler (E),or a combination of the latter two.

In some instances, the catalyst (C) is present in a separate part fromthe organopolysiloxane (B) and the inhibitor (D).

The other or optional additives may be in any of part I or II or in bothparts. They may also be added after parts I and II have been combined.

The mixture may be prepared by providing for at least 3 separate parts,such as part I, part II and part III. Parts I and II may be provided asabove. Part III may contain any of organopolysiloxane (A),organopolysiloxane (B), the catalyst (C), the inhibitor (D), the silicafiller (E) or specific additives such as pigments, filler different fromsilica filler (E), which may be present as may be required by the finaluse of the composition.

Subsequently the different parts are combined together and homogeneouslymixed, with the optional subsequent step of the addition of anyadditional additive as may be required by the final use of thecomposition.

Typically, the at least two parts are combined within the mixing deviceand injected to be printed. In some instances, the at least two partsmay be combined prior to their injection in the printing device.

The dynamic viscosity of the final 3D-printable silicone elastomercomposition may range of from 50 to 500 Pa·s, alternatively of from 50to 300 Pa·s, alternatively of from 100 to 250 Pa·s as measured at roomtemperature, at a shear rate of 10 s⁻¹, using a plate-plate rheometer,according to standard method DIN53018.

The present 3D-printable silicone rubber composition may produce3D-printed objects/articles having hardness (or durometer) in the rangeof 10-90 Shore A, alternatively 20-90 Shore A, alternatively 30-70 ShoreA. Shore A durometer is typically measured using ASTM D2240-15. Theterms hardness and durometer may be used interchangeably in the scope ofthe present invention.

The Shore A scale is most common for soft elastomeric materials, whilethe Shore D scale is used for harder materials such as plastics. A rangeof 80-90 Shore A typically corresponds to about 30-40 Shore D.

The present 3D-printed objects/articles obtained from printing/curingthe 3D-printable silicone rubber composition include those that may beused in producing sports products, diving masks, ventilator bellows,balloon catheters, rubber teats, pacifiers, thin-walled membranes,switch covers, spark-plug connectors, medical products and devices,electrical insulators, single-wire seals, plug connector seals, tubingand valves, automobile components such as connector seal and spark plugboots, electric and electronic parts such as rolls in a copying machineand packing in a microwave oven; as well as other products such asfeeding bottle nipple and diving gears, in view of the high heatresistance, cold resistance, safety, electric insulation,weatherability, and the like.

As an example, the 3D-printable composition includes:

-   -   A1: vinyldimethylsiloxy-endblocked polydimethylsiloxane having a        viscosity of approximately 53,000 mPa·s at 25 ° C.    -   A2: vinyldimethylsiloxy-endblocked        dimethylsiloxane-vinylmethylsiloxane copolymer having a        viscosity of approximately 360 mPa·s at 25 ° C.    -   B: Me₃SiO_(0.5) terminal        poly(dimethyl-co-methylhydrogen)siloxane having a viscosity of        approximately 50 mPa·s at 25 ° C.    -   C: divinyltetramethyldisiloxane complex of platinum    -   D: 1-ethynyl-l-cyclohexanol    -   E: fumed silica filler having a surface area of approximately        300 m² g; hydrophobized; having a vinyl functionalization of        approximately 0.08 mmol/g    -   Further additive: OH terminal PDMS with a viscosity of        approximately 21 mPa·s at 25 ° C.

Said composition has a final viscosity of 120 to 200 Pa·s, beforecuring. The composition is provided in two parts and combined in theprinting head, before the nozzle. Printed objects provided (i.e. readilyprocessed articles) have a tensile strength of 5.71±0.23 MPa and anelongation at break of 332.60±12.19% when tested according toDIN53504-52; and a tear strength of 39.58±1.24 N/mm when testedaccording to ASTM D-624-B.

FIG. 4A to FIG. 4F illustrate a printing device 100 in various views,according to various embodiments, in a similar way, as described above.

According to various embodiments, the printing device 100 may include ahousing structure 400 to mount the components of the printing device100, e.g., to mount a printing platen 106, a movably arranged printinghead 102, a movably arranged rod-shaped heating device 108, as well ascontrollers, motors, etc.

As illustrated for example in FIG. 4A, the printing platen 106 may bemovably arranged, e.g., to move in z-direction. A pluraltiy of threadedrods 442 may be used to move the printing platen 106 via rotating thethreaded rods 442. The threaded rods 442 may be driven by one or moremotors coupled to the threaded rods 442. These one or more motors may bedriven by a motor control circuit, according to various embodiments.

According to various embodiments, a guiding structure 402 (e.g., aguiding frame) may be used to provide a movable arrangement includingthe rod-shaped heating device 108 and the printing head 102. The guidingstructure 402 may be linearly movably arranged (e.g., to be moved alongthe x-direction), e.g., the guiding structure 402 may be movably mountedon one or more rails. In this case, the rod-shaped heating device 108and the printing head 102 may be linearly moved at the same time (e.g.,along the x-direction). A motor arrangement 438 may be used to move theguiding structure 402, i.e. to move the printing head 102 and therod-shaped heating device 108. According to various embodiments, themovement of the guiding structure 402 may be driven by one or moremotors coupled to the guiding structure 402, for example via a belt(e.g., via a toothed belt). These one or more motors may be driven by amotor control circuit, according to various embodiments.

According to various embodiments, the rod-shaped heating device 108 maybe fixed at the guiding structure 402, e.g., via one or more carrierelements. One or more electrical supply lines may be coupled to therod-shaped heating device 108 to generate heat radiation, wherein theone or more electrical supply lines may be attached to the guidingstructure 402. The rod-shaped heating device 108 may be aligned inparallel to the printing platen 106 in a fixed distance. According tovarious embodiments, the printing head 102 may be movably mounted at theguiding structure 402. The printing head 102 may be linearly movablyarranged (e.g., to be moved along the y-direction). According to variousembodiments, the movement of the printing head 102 may be driven by oneor more motors coupled to the printing head 102. The movement of theseone or more motors may be controlled by a motor control circuit,according to various embodiments. The motors for moving the printingplaten 106, the guiding structure 402 together with the printing head102 and the rod-shaped heating device 108 and for moving the printinghead 102 relative to the guiding structure 402 may allow printingthree-dimensional objects on the printing platen 106. The motor controlcircuits for controlling the X,Y,Z-movement may be part of at least onemotor controller 148.

Further, a dosage controller 214 may be mounted at the housing structure400.

As illustrated for example in FIG. 4B and FIG. 4C, a printing head 102may be movably mounted at the guiding structure 402. Illustratively, theguiding structure 402 may provide a support frame to carry the printinghead 102 and the rod-shaped heating device 108.

According to various embodiments, the two printing material components204 a, 204 b may be fed from the respective containers 202 a, 202 b,e.g., unmixed, to the dispenser 304. The dispenser 304 may include twoseparately controllable pumps 404 a, 404 b. For example, a separatelycontrollable pump 404 a, 404 b may be used for conveying each of the twoprinting material components 204 a, 204 b. The pumps 404 a, 404 b may beconfigured to feed at least two printing material components 204 a, 204b to a reservoir 202, and subsequently to a mixer 304 m (e.g., to astatic mixer including screw mixing channels) in a controlled manner.The mixer 304 m may be arranged to receive the material output of thepumps 404 a, 404 b. According to various embodiments, a nozzle 304 n, asdescribed above, may be screwed on a portion of the mixer 304 m.

According to various embodiments, each of the printing materialcomponents 204 a, 204 b may be provided with a pressure in the rangefrom about 1 bar to 3 bar, e.g., with a pressure of about 2 bar, to therespective pump input of the pumps 404 a, 404 b. The pressure may beprovided by compressed air or by another suitable setup. The pumps 404a, 404 b may be configured as screw conveyors including at least onescrew element for controlling the material output based on rotationalspeed and/or number of rotations of the at least one screw element. Thepumps 404 a, 404 b may be configured to feed the printing materialcomponents 204 a, 204 b to the mixer 304 m in a predefined mixing ratio.According to various embodiments, the mixing ratio may be adjusted to apredefined value by controlling rotational speed and/or number ofrotations of the at least one screw element of the respective pump 404a, 404 b. Both pump outputs may be coupled to a reservoir 202 andsubsequently to the mixer 304 m.

The printing head 102 may include two cartridges 202 a, 202 b (e.g., twopre-reservoir) connected to the dispenser 304, wherein the printingmaterial components 204 a, 204 b may be stored in the two cartridges 202a, 202 b to feed the printing material components 204 a, 204 b to thedispenser 304. Alternatively, the printing material components 204 a,204 b may be fed directly to the dispenser 304 from any suitablecontainer via one or more supply lines.

According to various embodiments, the compressed air supply (e.g., witha pressure of about 2 bar) may be provided to the cartridges 202 a, 202b by pressure lines 408 (e.g., hoses or tubes). According to variousembodiments, pump motors 414 a, 414 b may be coupled to the pumps 404 a,404 b respectively. The pump motors 414 a, 414 b may be supplied withpower by one or more electrical supply lines 406. According to variousembodiments, movement of the pump motors 414 a, 414 b may be controlledby the dosage controller 214. The mixing ratio of the printing materialcomponents 204 a, 204 b may be controlled by the rotation-ratio orrpm-ratio of the pump motors 414 a, 414 b.

According to various embodiments, the pumps 404 a, 404 b, the pumpmotors 414 a, 414 b, and the reservoir 202 may be part of the dispenser.

As illustrated for example in FIGS. 4D and FIGS. 4E, the rod-shapedheating device 108 may be fixed to the guiding structure 402 to emitheat into the direction of the printing platen 106. The rod-shapedheating device 108 may include a heat shield 408 s and or a reflector.The heat shield 408 s may include or may be made of at least one metal,e.g., aluminum, silver, gold, and the like. An IR-rod 408 e may be usedto emit IR-radiation.

According to various embodiments, after a layer has been printed, theprinting head 102 may be moved to an edge of the guiding structure 402into a waiting position. Afterwards, the rod-shaped heating device 108may be activated and driven over the printing platen 106 (e.g., alongthe y-direction). The rod-shaped heating device 108 may be driven onceforwards and backwards over the printing platen 106 for each of theprinted layers. Afterwards, the rod-shaped heating device 108 may bedeactivated, and the printing head 102 may be moved from the waitingposition back into an operating position.

According to various embodiments, the material flow (i.e. the volumeoutput) of the printing material 104 through the nozzle (i.e. thematerial output) and the mixing ratio of the printing material 104 maybe controlled by the dosage controller 214, exemplarily shown in FIG.4F.

The volume output may be determined based on printing head movementparameters (e.g., Step/Gear/Direction) generating the desired layer ofthe three-dimensional object. The volume output may be determined as amaterial flow, i.e. volume output per time. Therefore, the dosagecontroller 214 may determine the motor-rotations or motor-rotations pertime (rounds per minute, rpm, or rounds per second, rps) to provide thedesired material flow and therefore the desired volume output.

The motor-rotations or motor-rotations per time may be divided acrossthe pump motors 414 a, 414 b in accordance with a pre-defined ratio, thepre-defined ratio representing the mixing ratio for the printingmaterial components 204 a, 204 b conveyed by the pumps 404 a, 404 brotated by the pump motors 414 a, 414 b.

For example, eight rotations may be divided across the pump motors 414a, 414 b into four rotations for each of the pump motors 414 a, 414 b ifthe pre-defined ratio is 1:1. According to various embodiments, themixing ratio and therefore the pre-defined ratio for driving the pumpmotors 414 a, 414 b may be fixed or variable during operation of theprinting device 100. The dosage controller 214 may include an interface414 i for selecting and/or changing the pre-defined ratio.

According to various embodiments, the rod-shaped heating device 108 mayinclude one or more glass tubes, e.g., made of high quality quartzglass. The rod-shaped heating device 108 may be configured as a twintube radiator. According to various embodiments, each glass tube mayprovide a housing for at least one heating coil. The respective heatingcoil may be driven by an electrical current flow through the heatingcoil. The electrical current flow may be used to control the temperatureof the heating coil and therefore the electromagnetic wave spectrum ofthe radiation emitted by the heating coil. According to variousembodiments, the heating coil may be heated up to about 2000° C., e.g.,to a temperature greater than about 1500° C., to substantially emitshort-wave IR-radiation. According to various embodiments, a reflector(e.g., a metal layer, as for example a silver or gold layer) may bedisposed within the glass tube or outside the glass tube. The ramp timefor heating the heating coil up and cooling the heating coil down may beless than two seconds, e.g., in the range from about 1 s to about 2 s.

Various examples are provided in the following that are embodied asdescribed with reference to the figures or similar to the embodimentsdescribed above.

Example 1 is a device for mold-free (in other words form-free) printing(also referred to das additive manufacturing or 3D-printing) athree-dimensional object in (e.g., successively formed) layers using atleast one printing material, wherein the device may include: a printingplaten; at least one printing head configured to output (in other words,to print, e.g. to extrude or to string-shaped extrude) the at least oneprinting material and to form at least one printing material deposit onthe printing platen (via the at least one printing material output bythe at least one printing head); and a rod-shaped heating devicearranged over the printing platen in a moveable configuration allowingmovement of the rod-shaped heating device over the printing platen,wherein the rod-shaped heating device is configured to emit heatradiation directed at the printing platen to harden (in other words, tocure, activate, or trigger) the at least one printing material depositvia the heat radiation.

In Example 2, the device of Example 1 may optionally include that the atleast one printing head is configured to output the at least oneprinting material in a string-shape.

In Example 3, the device of Example 1 or 2 may optionally furtherinclude a motor arrangement configured to drive movement of therod-shaped heating device.

In Example 4, the device of Example 3 may optionally include that themotor arrangement includes at least one motor coupled to the rod-shapedheating device and at least one motor controller configured to controlthe driven movement of the rod-shaped heating device via the at leastone motor.

In Example 5, the device of any one of Examples 1 to 4 may optionallyfurther include a heating device controller configured to controlemission of the heat radiation from the rod-shaped heating device.

Example 6 is a device for mold-free (in other words form-free) printing(also referred to das additive manufacturing or 3D-printing) athree-dimensional object in (e.g., successively formed) layers using atleast one printing material, wherein the device may include: a printingplaten; at least one printing head configured to output (in other words,to print, e.g. to extrude or to string-shaped extrude) the at least oneprinting material and to form at least one printing material deposit onthe printing platen (via the at least one printing material output bythe at least one printing head); and a rod-shaped radiation emittingdevice arranged over the printing platen in a moveable configurationallowing movement of the rod-shaped radiation emitting device over theprinting platen, wherein the rod-shaped radiation emitting device isconfigured to emit radiation directed at the printing platen to harden(in other words to cure, activate, or trigger) the at least one printingmaterial deposit via the radiation.

Example 7 is a device for mold-free (in other words form-free) printing(also referred to das additive manufacturing or 3D-printing) athree-dimensional object in (e.g., successively formed) layers using atleast one reactive printing material, wherein the device may include: aprinting platen; at least one printing head configured to output (inother words, to print, e.g. to extrude or to string-shaped extrude) theat least one reactive printing material and to form at least onereactive printing material deposit on the printing platen (via the atleast one printing material output by the at least one printing head);and a rod-shaped radiation emitting device arranged over the printingplaten in a moveable configuration allowing movement of the rod-shapedradiation emitting device over the printing platen, wherein therod-shaped radiation emitting device is configured to emit radiationdirected at the printing platen to activate a chemical reaction in theat least one reactive printing material deposit via the radiation.

In Example 8, the device of Example 6 or 7 may optionally include thatthe at least one printing head is configured to output the at least oneprinting material in a string-shape.

In Example 9, the device of any one of Examples 6 to 8 may optionallyfurther include a motor arrangement configured to drive movement of therod-shaped radiation emitting device.

In Example 10, the device of Example 9 may optionally include that themotor arrangement includes at least one motor coupled to the rod-shapedradiation emitting device and at least one motor controller configuredto control the driven movement of the rod-shaped radiation emittingdevice via the at least one motor.

In Example 11, the device of any one of Examples 6 to 10 may optionallyfurther include a radiation emitting device controller configured tocontrol emission of the radiation from the rod-shaped radiation emittingdevice.

According to various embodiments, a device for mold-free printing athree-dimensional object in layers using at least one printing materialmay include: a printing platen; at least one printing head configured tooutput the at least one printing material in a string-shape and to format least one printing material deposit on the printing platen (via theat least one printing material output by the at least one printinghead); and a rod-shaped heating device arranged over the printing platenin a moveable configuration allowing movement of the rod-shaped heatingdevice over the printing platen, wherein the rod-shaped heating deviceis configured to emit heat radiation directed at the printing platen toharden the at least one printing material deposit via the heatradiation.

According to various embodiments, a device for mold-free printing athree-dimensional object in layers using at least one printing materialmay include: a printing platen; at least one printing head configured tooutput the at least one printing material in a string-shape and to forma deposit layer on the printing platen via the at least one printingmaterial output by the at least one printing head; and a rod-shapedheating device arranged over the printing platen in a moveableconfiguration allowing movement of the rod-shaped heating device overthe printing platen, wherein the rod-shaped heating device is configuredto emit heat radiation directed at the printing platen to harden thedeposit layer via the heat radiation.

According to various embodiments, the rod-shaped heating devicecomprises a rod-shaped lamp. According to various embodiments, therod-shaped lamp may be a rod-shaped infrared emitting lamp. According tovarious embodiments, the rod-shaped lamp may be configured to emit lighthaving a wavelength in the range from about 780 nm to about 1 mm.According to various embodiments, the rod-shaped lamp may be configuredto emit light having a wavelength in the range from about 780 nm toabout 12 gm, e.g., in the range from about 780 nm to about 5 gm, e.g.,in the range from about 780 nm to about 2.5 gm, e.g., in the range fromabout 900 nm to about 2.5 gm. According to various embodiments, therod-shaped lamp may have a length of approximately the same or greaterthan the width of the printing platen. In this case, the emitted heatradiation may be irradiated on substantially the entire width of theprinting platen. According to various embodiments, the rod-shapedheating device may be linearly movably arranged over the printingplaten.

According to various embodiments, moving a rod-shaped heating device ora rod-shaped radiation emitting device, e.g., linearly, over theprinting platen may allow homogenously irradiating the printing materialdeposit layer formed on the printing platen. A spot-wise irradiation oran irradiation of the entire surface of the printing platen at once maybe less homogeneous as moving the rod-shaped heating device or therod-shaped radiation emitting device over the printing platen, asdescribed herein. According to various embodiments, the movement speedfor moving the rod-shaped heating device or the rod-shaped radiationemitting device over the printing platen may be fixed to a pre-definedvalue to obtain a homogeneous irradiation. According to variousembodiments, the movement direction for moving the rod-shaped heatingdevice or the rod-shaped radiation emitting device over the printingplaten may be switched once from forwards to backwards (e.g., from afirst direction to a second direction anti-parallel to the firstdirection) for each of the layers of printing material depositsuccessively formed.

In Example 12, the device of any one of Examples 1 to 11 may optionallyfurther include a reservoir to receive the at least one printingmaterial. The reservoir may be coupled to the at least one printing headto supply the at least one printing material to the at least oneprinting head.

In Example 13, the device of any one of Examples 1 to 11 may optionallyfurther include: a first pre-reservoir to receive a first pre-printingliquid; and a second pre-reservoir to receive a second pre-printingliquid; and a reservoir to receive the first pre-printing liquid and thesecond pre-printing liquid and to provide the at least one printingmaterial from the first pre-printing liquid and the second pre-printingliquid. According to various embodiments, the first pre-printing liquidand the second pre-printing liquid may be components of a two-componentreactive printing material.

In Example 14, the device of Example 13 may optionally further include:a dosage controller configured to dose the at least one printingmaterial supplied to the reservoir. According to various embodiments,the dosage controller may be configured to dose the amount of firstpre-printing liquid and the amount of second pre-printing liquidsupplied to the reservoir.

According to various embodiments, the motor controller may be furtherconfigured to control the at least one motor to move the rod-shapedheating device or rod-shaped radiation emitting device over the printingplaten at least once each time after a respective layer of the at leastone printing material deposit has been formed. According to variousembodiments, the motor controller may be further configured to controlthe at least one motor to move the rod-shaped heating device orrod-shaped radiation emitting device over the printing platen two timeseach time after a respective layer of the at least one printing materialdeposit has been formed.

According to various embodiments, the heating device controller (alsoreferred to as heat controller) may be further configured to control therod-shaped heating device to emit a heat radiation directed to theprinting platen to heat the printing material deposit to a reactiontemperature of the at least one printing material of the at least oneprinting material deposit. According to various embodiments, theradiation emitting device controller may be further configured tocontrol the rod-shaped radiation emitting device to emit a radiationdirected to the printing platen to trigger a chemical reaction in theprinting material deposit.

While the invention has been particularly shown and described withreference to specific embodiments, it should be understood by thoseskilled in the art that various changes in form and detail may be madetherein without departing from the spirit and scope of the invention asdefined by the appended claims. The scope of the invention is thusindicated by the appended claims and all changes which come within themeaning and range of equivalency of the claims are therefore intended tobe embraced.

1. A device for formfree printing a three-dimensional object in layersusing at least one printing material, the device comprising: at leastone printing head to output printing material in at least one printingmaterial string in string-shape; a printing platen to receive the atleast one printing material string output by the at least one printinghead; a rod-shaped heating device movably arranged over the printingplaten; a heat controller configured to control the rod-shaped heatingdevice to emit a heat irradiation directed to the printing platen toheat the at least one printing material string to a reaction temperatureto trigger a chemical reaction of the at least one printing material ofthe at least one printing material string; at least one motor coupled tothe rod-shaped heating device to move it over the printing platen; amotor controller configured to control the at least one motor to movethe rod-shaped heating device over the printing platen to harden the atleast one printing material string printed on the printing platen. 2.The device of claim 1, wherein the rod-shaped heating device comprises arod-shaped lamp.
 3. The device of claim 2, wherein the rod-shaped lampis configured to emit light having a wavelength in the range from about780 nm to about 12 μm.
 4. The device of claim 3, wherein the rod-shapedlamp is a rod-shaped infrared lamp.
 5. The device of claim 2, whereinthe rod-shaped lamp has a length of approximately the same or higherthan the width of the printing platen so that the irradiated heat isirradiated on substantially the entire width of the printing platen. 6.The device of claim 1, further comprising a reservoir to receive the atleast one printing material, wherein the reservoir is coupled to the atleast one printing head to supply the at least one printing material tothe at least one printing head.
 7. The device of claim 1, furthercomprising: a first pre-reservoir to receive a first pre-printingliquid; a second pre-reservoir to receive a second pre-printing liquid;and a reservoir to receive the first pre-printing liquid and the secondpre-printing liquid and to provide the at least one printing materialfrom the first pre-printing liquid and the second pre-printing liquid.8. The device of claim 1, wherein the rod-shaped heating device islinearly movably arranged over the printing platen.
 9. The device ofclaim 6, further comprising a dosage controller configured to dose theat least one printing material supplied to the reservoir.
 10. The deviceof claim 7, further comprising a dosage controller configured to dosethe amount of first pre-printing liquid and the amount of secondpre-printing liquid supplied to the reservoir.
 11. The device of claim1, wherein the motor controller is further configured to control the atleast one motor to move the rod-shaped heating device over the printingplaten at least once each time after a respective layer of the at leastone printing material string has been printed on the printing platen.12. A method of formfree printing a three-dimensional object in layerswith at least one printing material, the method comprising: outputtingprinting material in at least one printing material string instring-shape via at least one printing head; receiving, via a printingplaten, at least one printing material string output by the at least oneprinting head; providing a rod-shaped heating device movably arrangedover the printing platen; controlling the rod-shaped heating device, viaa heat controller, to emit a heat irradiation directed to the printingplaten to heat the at least one printing material string to a reactiontemperature to trigger a chemical reaction of the at least one printingmaterial of the at least one printing material string; providing atleast one motor coupled to the rod-shaped heating device to move therod-shaped heating device over the printing platen; and controlling theat least one motor, via a motor controller, to move the rod-shapedheating device over the printing platen to harden the at least oneprinting material string printed on the printing platen.
 13. A method offormfree printing a three-dimensional object in layers in accordancewith claim 12, wherein the at least one printing material may compriseone or more reactive liquid materials, which may be injected in theprinting device and cure/react upon heating to form a printed object orat least one printed layer of an object.
 14. A method of formfreeprinting a three-dimensional object in layers in accordance with claim12, wherein the at least one printing material may be a resin, which maybe cured by UV light; silicone rubbers, and/or thermoplastics, such asacrylonitrile butadiene styrene (ABS), polycarbonate, nylon,polyetherimide (PEI) resin.
 15. A method of formfree printing athree-dimensional object in layers in accordance with claim 13, whereinthe at least one printing material comprises a 3D-printable siliconerubber composition.
 16. A method of formfree printing athree-dimensional object in layers in accordance with claim 15, whereinthe 3D-printable silicone rubber composition comprises: a firstorganopolysiloxane containing at least 2 alkenyl groups bonded tosilicon atom per molecule, in an amount of from 35 to 85% by weight,based on the total weight of the composition; a secondorganopolysiloxane containing at least 3 silicon-bonded hydrogen atomper molecule, in an amount of from 0.1 to 15% by weight, based on thetotal weight of the composition; a platinum based catalyst, in aquantity of platinum atom that provides of from 0.1 to 500 weight-ppm(parts per million) of platinum atom in the catalyst based on the totalweight of the reactive first and second organopolysiloxanes; aninhibitor selected from the group consisting of acetylenic alcohols andtheir derivatives, in an amount of from 10 to 50,000 weight-ppm in the3D-printable elastomer composition; a silica filler, in an amount offrom 10 to 40% by weight, based on the total weight of the composition;and optional additives, in an amount of from 0 to 10% by weight based onthe total weight of the composition, alternatively 0.1 to 10% by weightbased on the total weight of the composition.